© MAR 2019 | IRE Journals | Volume 2 Issue 9 | ISSN: 2456-8880

Utilization of Blast Furnace Slag in Manufacturing of

Paver Blocks
DAWARE SANKET S.1, PHADATARE SHITAL U.2, SALVI SHUBHAM P.3, A. B. SAWANT4,
V. H. LAVANGARE5
1,2,3,4,5
Dept. of Civil Engineering, KIT CoE, Kolhapur, Shivaji University, Kolhapur

Abstract - To meet the global demand of concrete in the
future, it is becoming a more challenging task to find
suitable alternatives to natural aggregates for preparing
concrete, hence the use of alternative sources for natural
aggregates is becoming increasingly important. Slag is a
co-product of the iron and steel making process. Iron
cannot be prepared in the blast furnace without the
production of its co-product i.e. induction furnace slag.
The use of induction furnace slag aggregates in concrete
by replacing natural aggregates is a most promising
concept because its impact strength is more than the
natural aggregate. Steel slag aggregates are already being
used as aggregates in asphalt paving road mixes due to
their mechanical strength, stiffness, porosity, wear
resistance and water absorption capacity.
Experimental program is planned to study the
following objectives-
a) The purpose of this research is to explore the
feasibility of utilizing the induction furnace slag
as a replacement for natural aggregate in the
concrete.
b) The original scope of this research is to
investigate the properties of concrete with
induction furnace slag aggregates.
c) To study the effect on compressive strength of
concrete with induction furnace slag.

I. INTRODUCTION
Now-a-days disposal of different waste produced
from different Industries is a great problem. These
materials pose environmental pollution in the nearby
locality because many of them are non-
biodegradable. The construction sector is exploring
rapidly on a large scale and also involves new
techniques for rapid and comfort works on the field.
Concrete as a building material plays an important
role in this sector. The consumption of natural
resources as an ingredient of concrete, costs high it is
on verge of extinct. These problems force us to
recover the natural resources or to find replacement.
Concrete is a material which is composed of coarse
aggregate, fine aggregate, cement, admixtures and
water. Each material in concrete contributes in its
strength and durability, so by partial or percentage
replacing of material affects different properties of
concrete. Using such waste material which harms the
environment can be used for the development of low
cost and eco-friendly structural materials. In this
study an experimental investigation will be carried
out by varying percentage of coarse aggregate, with
used induction furnace slag to produce low cost and
eco-friendly concrete.
II. SLAG
A. Manufacturing Process:
During production of iron, steel, iron scrap, steel
scrap and fluxes (limestone and/or dolomite) are
charged into a blast furnace along with coke for fuel.
The coke is combusted to produce carbon monoxide,
which reduces the iron ore to a molten iron product.
When the blast furnace is tapped to release the
molten iron, it flows from the furnace with molten
slag floating on its upper surface. These two
materials are separated using a weir, the molten iron
being channeled to a holding vessel and the molten
slag to a point where it into be treated further. Slag is
formed by the fusion of iron ore impurities after the
fluxing agents (limestone and dolomite) and coke
ashes are added to the mix. The melted slag is an
insoluble and lower density mass which floats on the
pig iron and is tapped through runners into a cooling
place. Iron and steel slag refers to the type of metal
manufacturing slag that is generated during the
process of manufacturing iron and steel products. The
term "slag" originally referred to slag produced by
metal manufacturing processes, however it is now
also used to describe slag that originates from molten
waste material when trash and other substances are
disposed. The final form of the slag is dependent on

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the method of cooling and can be produced in the cement to ensure that it confirms to the requirements
following forms: of the IS specifications. The physical properties of
the cement were determined as per IS: 4031-1968
B. Types: and are presented in following table.
Different types of slag are produced according the
different procedures used to cool the molten slag. We Table 1: Properties of Cement
have used the induction furnace slag which is air Sr.
Type of Test Results
cooled type slag No.
1 Fineness of Cement (%) 1.55 %
a) Granulated:
The molten slag is cooled rapidly by jets of 2 Standard Consistency (%) 31.00 %
pressurized water, resulting in a vitreous,
granulated 3 Initial Setting Time (min) 275 min

b) Air-cooled: 4 Final Setting Time (min) 342 min

The molten slag flows into a cooling yard, where it
5 Specific gravity 3.15
is cooled slowly by natural cooling and by spraying
with water. This results in a crystalline, rock-like 7 Day’s Compressive 35.425
6
Strength N/mm2
air-cooled slag.
28 Day’s Compressive 46.150
7
Strength N/mm2
c) Pelletised:
If the molten slag is cooled and solidified with
water and air quenched in a spinning drum, pellets b) Coarse Aggregate
rather than a solid mass, can be produced. By Table 2: Properties of Coarse Aggregate
controlling the process, the pellets can be made Sr.
Properties Value
more crystalline, which is beneficial for aggregate No.
use, or more vitrified (glassy), which is more 1 Specific Gravity 3.05
desirable in cementations applications. More rapid 2 Fineness Modulus 3.43
quenching results in greater nitrification and less 3 Water Absorption 0.5%
crystallization
c) Fine Aggregate
d) Foamed:
If the molten slag is cooled and solidified by Table 3: Properties of Fine Aggregate
adding controlled quantities of water, air, or steam, Sr.
Properties Value
the process of cooling and solidification can be No.
accelerated, increasing the cellular nature of the 1 Specific Gravity 2.83
slag and producing a lightweight expanded or 2 Fineness Modulus 2.79
foamed product. Foamed slag is distinguishable 3 Water Absorption 0.45%
from air-cooled blast furnace slag by its relatively
high porosity and low bulk density.
d) Induction Furnace Slag

Sourabh Metals, a machine part manufacturing

III. MATERIAL AND CONCRETE DESIGN MIX
industry is situated Gokul-Shirgaon, Kolhapur. When
DETAILS
the induction furnace is tapped to release the molten
A. Material iron, it flows from the furnace with molten slag
floating on its upper surface. These two materials are
a) Cement separated using a weir, the molten iron being
channelled to a holding vessel after which that
Ordinary Portland cement (Birla 43 Grade)
molten iron going to be pour into moulds of machine
confirming to IS: 269-1976 was used throughout the
parts and the molten slag to a point where it is to be
investigation. Different tests were performed on the

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 © MAR 2019 | IRE Journals | Volume 2 Issue 9 | ISSN: 2456-8880

treated further and according to treatment the slag is Table 7: ID Marks according to replacement
classified. And it is dumped on the sides i.e. on dry
I.D. for Percentage of Percentage of
places so as to cooled by air ; hence not so much
Paver Coarse Induction Furnace
expenditure is required for maintaining these sites Blocks aggregate Slag (IFS)
and disposal of wastes.
A 100 0
Induction furnace slag is greyish-black in color. Its
characteristics depend on the nature of iron ore used B 80 20
in the extraction of iron, which significantly differs
C 60 40
from place to place.
D 40 60
For the purpose of present experimental work,
induction furnace slag was procured from Sourabh
Metals. The material was crushed and sieved and Table 8: 7 Days Compressive Strength
induction furnace slag passing through 10 mm sieve Avg. 7 Days
and retaining on 4.75mm is used for our experimental Comp.
Block Load Compressive
Strength
work. ID (kN) Strength
(N/mm2)
(Mpa)
Table 4: Properties of Slag 0 % Replacement
Sr.
Properties Value A1 865.57 17.14
No.
A2 886.78 17.56 17.34
1 Specific Gravity 2.48
A3 873.65 17.3
2 Fineness Modulus 1.34 20 % Replacement
B1 850.42 16.84
3 Water Absorption 0.15 %
B2 830.22 16.44 16.35
B3 797.9 15.8
B. M20 Concrete Mix Design
40 % Replacement
a) Final Mix Proportion and Ratio C1 680.74 13.48
C2 699.93 13.86 13.54
Table 5: Properties of Slag
Coarse C3 671.65 13.3
Ceme Chemic
Sand Aggrega Water 60 % Replacement
nt al
te
D1 666.6 13.2
1% of
350 1135.48 935.549 164.5 D2 626.2 12.4 12.68
Cement
D3 628.725 12.45

Table 6: Properties of Slag

Coarse
Table 9: 28 Days Compressive Strength
Ceme Chemic
Sand Aggrega Water Avg. 7 Days
nt al Comp.
te Block Load Compressive
Strength
ID (kN) Strength
1 3.24 2.67 0.47 0.01 (N/mm2)
(Mpa)
0 % Replacement
IV. RESULT ANALYSIS A1 1334.21 26.42
A2 1356.43 26.86 26.76
Paver blocks having area 50500 mm2 and casted with
A3 1363.5 27
different % of replacement was tested under digital
Compression Testing Machine after the curing period 20 % Replacement
of 7 days & 28 days. B1 1199.88 23.76 23.73

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Avg. 7 Days V. DISCUSSION ON EXPERIMENTAL WORK

Comp.
Block Load Compressive
Strength The effect of the % replacement of coarse aggregates
ID (kN) Strength
(N/mm2)
(Mpa) by induction furnace slag on the compressive strength
B2 1184.23 23.45 of paver blocks was determined by testing of the
B3 1210.49 23.97 paver blocks in the compressive testing machine after
curing period of 7 days & 28 days and the results are
40 % Replacement
tabulated in table 2 & table 3
C1 1053.43 20.86
C2 1093.83 21.66 21.34 With reference to the tables and graphs (fig 1 to 2) it
C3 1085.75 21.5 is interesting to note that for both 7 days & 28 days
60 % Replacement IFS Concrete with 20% replacement of Coarse
D1 957.48 18.96 Aggregate with Induction Furnace Slag give
maximum Compressive Strength than that of other
D2 914.05 18.1 18.65
replacements. Then afterwards as we goes on
D3 954.45 18.9
increasing the % replacement of coarse aggregate by
IFS compressive strength goes on decreasing.

VI. CONCLUSION

The main aim of this research was to study the

Graph 1: 7 Days Compressive Strength
behavior of concrete and changes in the properties of
concrete with induction furnace slag aggregates by
replacing the use of natural aggregates. Induction
furnace slag is a byproduct and using it as aggregates
in concrete will might prove an economical and
environmentally friendly solution. The demand for
aggregates is increasing rapidly and so as the
demand of concrete. Thus, it is becoming more
important to find suitable alternatives for aggregates
in the future.

The IFS contains higher percentage of CaO that

reacts with silica after 28 days and produces extra gel
in the concrete. This extra quantity of gel increases
the gel/space ratio and reduces the porosity of
concrete, resulting in its higher compressive strength.

The compressive strength of 20% replacement by IFS

Graph 2: 28 Days Compressive Strength
aggregate concrete is marginally lower than that of
the stone aggregate concrete at the age of 7 days
while, no significant difference is observed at the age
of 28 days. Thus, IFS as a replacement of aggregates
performs well in concrete.

The results of the research program can be conclude

that even though the compressive strength of 20%
replacement is more amongst all the replacement but
our design is for M20 grade concrete and the results

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obtained for 40% material replacement are also Concrete. Volume 4, International Journal of
more than 20MPa and also 40% coarse aggregates Scientific & Engineering Research.
are replaced by Induction Furnace Slag (IFS). So it [13] Mohammed, N. and Pofale Arun, D. (2012).
can be finally concluded that 40% material “Utilization of Industrial Waste Slag as
replacement results are good and also the 40% Aggregate in Concrete Applications by
utilization of Induction Furnace Slag (IFS) is done in Adopting Taguchi’s Approach for
concrete. Optimization”, Volume-2, pp 96-105. Journal
of Civil Engineering
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